Liquid crystal displays using organic insulating material and manufacturing methods thereof

ABSTRACT

A passivation layer is formed by coating a flowable insulating material on the substrate where a thin film transistor and a storage capacitor electrode, and a pixel electrode is formed on the passivation layer. A portion of the passivation layer is etched using the pixel electrode as a mask to make a groove on the thin film transistor, and then a black matrix is formed by filling an organic black photoresist in the groove. To increase the storage capacitance, a portion of the passivation layer is removed or to form a metal pattern on the storage capacitor electrode. A flowable insulating material is used as a gate insulating layer to planarize the substrate. In the case of the etch stopper type thin film transistor, a photo definable material is used as the etch stopper layer to reduce the parasitic capacitance between the gate electrode and the drain electrode.

BACKGROUND OF THE INVENTION

(a) Field of the Invention

The present invention relates to a thin film transistor liquid crystaldisplay, more specifically to a thin film transistor liquid crystaldisplay whose black matrix is formed on a thin film transistorsubstrate.

(b) Description of the Related Art

Most liquid crystal displays include a thin film transistor (TFT)substrate and a color filter substrate. Black matrix is generally formedon the color filter substrate and is used to shield the light leakage inthe portions between pixels. However, misalignment between the TFTsubstrate and the color filter substrate may make it hard to shield thelight leakage perfectly. For that reason, a method of forming the blackmatrix on TFTs, which is called black matrix on TFT (BM on TFT), wasrecently suggested.

FIG. 1 illustrates a cross-sectional view of a conventional BM on TFTtype TFT substrate.

As shown in FIG. 1, a gate electrode 2 and a storage capacitor electrode3 are formed on a transparent substrate 1. A gate insulating layer 4 isformed on the gate electrode 2 and the storage capacitor electrode 3. Anamorphous silicon layer 5, an etch stopper layer 6 and an n+amorphoussilicon layer 7 are deposited sequentially on the gate insulating layer4 over the gate electrode 2. A source electrode 8 and a drain electrode9 are formed on the n+ amorphous silicon layer 7, and the sourceelectrode 8 is connected to a data line (not shown). The gate electrode2, the gate insulating layer 4, the amorphous silicon layer 5, the n+amorphous silicon layer 7, the source electrode 8 and the drainelectrode 9 form a TFT. A passivation layer 10 is formed on the TFT andthe gate insulating layer 4, and a black matrix 11 is formed on thepassivation layer 10 over the TFT. A pixel electrode 12 made of ITO(indium tin oxide) is formed on the passivation layer 10 in a pixelregion, and connected to the drain electrode 9 through a contact hole inthe passivation layer 10.

Because the pixel electrode 12 is close to the data line, couplingcapacitance is generated between the pixel electrode 12 and the dataline when the liquid crystal display is in operation, and the couplingcapacitance distorts the display signal.

Since the black matrix 11 is formed on the TFT, the height differencebetween the portions near the TFT and the pixel electrode 12 can becomelarger to make defects of the alignment layer, thereby causing leakage.Although the light leakage may be reduced by increasing the width of theblack matrix, in this case, the aperture ratio may decrease.

On the other hand, liquid crystal displays comprise two spaced parallelsubstrates and a liquid crystal layer therebetween. Spacers are insertedbetween the substrates to keep the cell gap, which is the thickness ofthe liquid crystal layer injected between two substrates, to beconstant. It is common to use spherical spacers having uniform size, andthe spacers are uniformly distributed on the pixel electrode 12. Becauseof the height difference in the color filter substrate and in the TFTsubstrate, it may be difficult to make a uniform cell gap. Therefore,the thickness of the liquid crystal layer becomes non-uniform, anddisplay characteristics become worse. Moreover, the spacers on the pixelelectrode 12 may cause a defect in the alignment layer and may cause thelight from the backlight unit to be scattered, thereby causing the lowtransmittance of the liquid crystal cell and the light leakage.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to allow a reductionin the coupling capacitance generated between a data line and a pixelelectrode.

It is another object of the present invention to allow a reduction inthe defect of the alignment layer.

It is yet another object of the present invention to allow an increasein the aperture ratio of liquid crystal display.

It is still another object of the present invention to allow the cellgap of a liquid crystal display to be uniform.

It is another object of the present invention to allow an increase inthe transmittance and a decrease in the light leakage by reducing thescattering of the back light.

These and other objects, features and advantages are provided, accordingto the present invention, by a liquid crystal display having apassivation layer made of a flowable insulating material. It ispreferable that the flowable insulating material is an organicinsulating material and has dielectric constant of 2.4-3.7. Thepassivation layer having a flat surface is formed on gate lines, datalines and TFTs in a TFT substrate to prevent the interference betweensignals of a pixel electrode formed on the passivation layer and of adata line formed under the passivation layer.

A portion of the passivation layer on gate lines, data lines and TFTs isremoved to make a groove, and a black matrix made of an organic blackphotoresist is filled in the groove.

The thickness of the passivation layer is preferably 2.0-4.0 μm to havesufficient insulating characteristics, and the thickness of the blackmatrix is preferably 0.5-1.7 μm.

In the pixel region, storage capacitor electrode is formed on atransparent substrate to form a storage capacitor with the pixelelectrode on the passivation layer. To increase the storage capacitance,the portion of the passivation layer on the storage capacitor electrodeis thinned or removed.

Another way to compensate the storage capacitance is, for example, tothin a portion of a gate insulating layer between the storage capacitorelectrode and the pixel electrode. In another embodiment, a contact holeexposing the storage capacitor electrode is formed in the gateinsulating layer, and a metal pattern is formed on the gate insulatinglayer and connected to the storage capacitor electrode through thecontact hole. Another embodiment provides a metal pattern connected tothe pixel electrode that may be formed on a portion of the gateinsulating layer on the storage capacitor electrode.

A flowable insulating layer is also used as a gate insulating layer suchthat the gate insulating layer may have a flat surface, and thus theparasitic capacitance between a gate electrode and a drain electrode canbe reduced. A silicon nitride layer may be formed between the flowablegate insulating layer and a semiconductor layer made of amorphoussilicon to prevent the interfacial characteristics of the amorphoussilicon layer from being deteriorated. It is preferable that an organicinsulating material is used and the thickness of the organic gateinsulating layer is preferably 2,500-5,500 Å. It is preferable that thethickness of the silicon nitride layer is 500-800 Å.

In the case of an etch stopper type TFT substrate, a photo definablematerial is used as an etch stopper layer to decrease the parasiticcapacitance between a gate electrode and a drain electrode and to makeprocess simple. It is preferable that an organic material is used andthe thickness of the etch stopper layer is 3,000-5,000 Å.

To keep a cell gap between a TFT substrate and a color filter substrate,spacers made of a photo definable organic material are formed on thecolor filter substrate. The spacers are formed between color filters,and they are formed at the position corresponding to TFTs on the TFTsubstrate.

To make a TFT substrate according to the present invention, a flowableinsulating layer which is to form a gate insulating layer is coated on asubstrate having a gate electrode. A silicon nitride layer is depositedon the flowable insulating layer. A semiconductor layer in formed on thesilicon nitride layer and the silicon nitride layer is etched awayexcept the portion under the semiconductor layer.

When an etch stopper layer is made of a photo definable material, aphoto definable organic layer is coated on the semiconductor layer andpatterned to form an etch stopper layer. The process of patterning theetch stopper layer includes the steps of exposing the organic layer tolight from the rear side of the substrate, exposing the organic layer tolight from the front side of the substrate using an etch stopper mask,developing the organic layer and annealing the organic layer.

Next, an ohmic contact layers a data pattern are formed sequentially. Aflowable insulating material, which is used for a passivation layer, iscoated, and a portion of the passivation layer on the storage capacitorelectrode is removed.

Then, an ITO (indium tin oxide) layer is deposited and patterned to makea pixel electrode in a pixel region, the passivation layer is etched toa depth using the pixel electrode as a mask, and an organic blackphotoresist is filled in the etched region flatly to form a blackmatrix.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a conventional BM on TFT substrate;

FIG. 2 shows a layout of a TFT substrate according to a first embodimentof the present invention.

FIG. 3 illustrates a cross-sectional view of a TFT substrate shown inFIG. 2 along the line III-III′.

FIGS. 4-11 are cross-sectional views of TFT substrates according tosecond to ninth embodiments respectively.

FIG. 12 illustrates a cross-sectional view of a color filter substrateaccording to an embodiment of the present invention.

FIG. 13 illustrates a cross-sectional view of a liquid crystal displaycell according to an embodiment of the present invention.

FIG. 14A illustrates a layout of a color filter substrate shown in FIG.12 to show the position of spacers.

FIG. 14B is a cross-sectional view of the color filter substrateillustrated in FIG. 14A along the line XIV-XIV′.

FIGS. 15A, 16A and 17A show layouts of intermediate structuresillustrating a method of manufacturing the TFT substrate according tothe first embodiment of the present invention.

FIGS. 15B, 16B and 17B illustrate cross-sectional views of the TFTsubstrate along with the line XV-XV′ of FIG. 15A, the line XVI-XVI′ ofFIG. 16A and the line XVII-XVII′ of FIG. 17A.

FIGS. 18 and 19 show cross-sectional views of intermediate structuresillustrating a method of manufacturing the TFT substrate according tothe sixth embodiment of the present invention.

FIGS. 20 and 21 show cross-sectional views of intermediate structuresillustrating a method of manufacturing the TFT substrate according tothe eighth embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the present invention are shown. This invention may, however, beembodied in different forms and should not be construed as limited tothe embodiments set forth herein. Rather, these embodiments are providedso that this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. In thedrawings, the thickness of layers and regions are exaggerated forclarity.

Liquid crystal displays according to the embodiment of the presentinvention comprise a liquid crystal cell comprising a TFT substrate anda color filter substrate, liquid crystal material injected into thecell, driving. ICs and peripheral devices.

FIG. 2 shows a layout of a TFT substrate according to a first embodimentof the present invention, and FIG. 3 illustrates a cross-sectional viewof a TFT substrate shown in FIG. 2 along the line III-III′.

As shown in FIGS. 2 and 3, a gate line 21 which transmits scanningsignals from the outside, a gate electrode 20 which is a branch of thegate line 21 and a storage capacitor electrode 30 which is parallel tothe gate line 21 are formed on a transparent insulating substrate 10such as glass. A gate insulating layer 40 is formed thereon.

A data line 81 which is perpendicular to the gate line 21 and transmitsdisplay signals from the outside is formed on the portion of gateinsulating layer 40. An amorphous silicon (a-Si) layer 50 is formed onthe gate insulating layer 40 on the gate electrode 20. An etch stopperlayer 60 and an ohmic contact layer 71 and 72 made of heavily dopedamorphous silicon with n type ions (n+ a-Si) are formed on the a-Silayer 50 in sequence. A source electrode 80 and a drain electrode 90 areformed on the ohmic contact layer 71 and 72 respectively, and the sourceelectrode 80 is connected to the data line 81.

Here, the gate electrode 20, the source electrode 80, the drainelectrode 90, the gate insulating layer 40, the ohmic contact layer 71and 72 and the a-Si layer 50 form a TFT, and the channel of the TFT isgenerated in the portion of the a-Si layer 50 between the sourceelectrode 80 and the drain electrode 90. When the scanning signal isapplied to the gate electrode 20 through the gate line 21, the TFT isturned on and the display signal which reaches the source electrode 80through the data line 81 flows into the drain electrode 90 through thechannel in the a-Si layer 50.

A passivation layer 100 having a flat surface is formed on the TFT andthe gate insulating layer 40. The passivation layer 100 is made of aflowable organic insulating material having low dielectric constant of2.4-3.7 and the thickness of 2.0-4.0 μm.

Compared with the silicon nitride layer which is generally used as apassivation layer, an organic insulating layer which is thicker by 10times than the silicon nitride layer has almost the same transmittance.For example, the organic insulating layer of 2.5 μm has the sametransmittance as the silicon nitride layer of 0.2 μm with respect to thevisible light.

Examples of flowable insulating materials are photo-BCB, BCB and PFCBproduced by Dow Chemical Co., acrylic photoresist produced by JSR Co.,and polyimide, and SOG (spin on glass) is also available. Since thosematerials are flowable, the passivation layer may have a flat surface byusing spin coating method.

The passivation layer 100 has a contact hole 130 exposing the drainelectrode 90, and the portion of the passivation layer 100 on thestorage capacitor electrode 30 is thinned to form a trench or is removedto expose the gate insulating layer 40. In a pixel region defined by thegate line 21 and the data line 81, a pixel electrode 140 made of ITO(indium tin oxide) is formed on the passivation layer 100. The pixelelectrode 140 is connected to the drain electrode 90 through the contacthole 130, and receives the display signal from the drain electrode 90 todrive liquid crystal molecules.

A portion of the passivation layer 100, which is not covered with thepixel electrode 140, is located on the TFT, the gate line 21 and thedata line 81, and is etched by a depth to make a groove. A black matrix110 made of an organic black photoresist is filled in the groove and hasa flat surface. The thickness of the black matrix 110 is 0.5-1.7 μm andthe optical density of the black matrix 110 is equal to or more than 2.5to have a sufficient light shielding characteristics. The thickness ofthe black matrix 110 may vary with the available material, andespecially the thickness depends on the optical density of the material.If the material having high optical density is used, the thickness ofthe black matrix can be decreased. Since the pixel electrode 140 is incontact with the passivation layer 100, it is preferable that the blackmatrix 110 has the high resistance, for instance, its surface resistanceis preferably equal to or more than 10¹⁰ Ω/□.

Carbon base organic materials or pigment type organic materials may beused as the black matrix 110, and since the carbon base organicmaterials have higher optical density than the pigment type materials,the carbon base organic materials are preferable. However, graphite typeorganic materials having high optical density may not be as good for theblack matrix because of its low surface resistance.

The storage capacitor electrode 30 and the pixel electrode 140 form astorage capacitor. Because there is thick passivation layer 100 betweenthe two electrodes 30 and 140, the storage capacitance may not besufficiently large. To compensate for the storage capacitance, theportion of the passivation layer between the two electrodes 30 and 140may be removed or become thinned.

The TFT substrate may have some other modified structures to compensatethe storage capacitance. FIGS. 4-6 illustrate cross-sectional views ofTFT substrates according to second to fourth embodiments of the presentinvention which are improved to compensate storage capacitance.

According to the second embodiment of the present invention, as shown inFIG. 4, the portion of the passivation layer 100 on the storagecapacitor electrode 30 is removed, and the portion of the gateinsulating layer 40 on the storage capacitor electrode 30 is thinnerthan the other portions. To keep the uniform thickness of the portion ofthe gate insulating layer 40 on the storage capacitor electrode 30, thegate insulating layer 40 may include two layers which have differentetch rates, and the portion of the upper layer on the storage capacitorelectrode 30 may be removed.

According to the third embodiment of the present invention, asillustrated in FIG. 5, a metal pattern 31 is formed on the portion ofthe gate insulating layer 40 on the storage capacitor electrode 30. Themetal pattern 31 is connected to the storage capacitor electrode 30through a contact hole 32 in the gate insulating layer 40, and coveredwith the passivation layer 100.

According to the fourth embodiment of the present invention, asillustrated in FIG. 6, a metal pattern 31 is formed on the portion ofthe gate insulating layer 40 on the storage capacitor electrode 30. Theportion of the passivation layer 100 on the metal pattern 31 is removedto form a contact hole 120, and the pixel electrode 140 covers the metalpattern 31 through the contact hole 120.

As described above, since the organic passivation layer 100 having lowdielectric constant is formed between the pixel electrode 140 and thedata line 81, the coupling capacitance between the pixel electrode 140and the data line 81 may be reduced, and thereby it is possible to makethe pixel electrode 140 to overlap the data line 81 and the gate line21. Accordingly, by decreasing the area which the black matrix occupiesand increasing the area which the pixel electrode occupies, the apertureratio of the TFT substrate can be enlarged.

In addition, since the black matrix 110 is formed on the TFT substrate,the photo induced leakage current due to the reflection of the backlight by the black matrix may be reduced. Moreover, because the surfaceof the TFT substrate is planarized, the problem of a defect in thealignment layer, which is caused by the height difference of thepattern, may be prevented or reduced.

FIG. 7 illustrates a cross-sectional view of an etch back type TFTsubstrate according to the fifth embodiment of the present invention,and the layout view of the TFT is substantially the same as FIG. 2. Thestructure of the TFT substrate according to this embodiment issubstantially the same as that according to the first embodiment shownin FIG. 3. However, the TFT of this embodiment does not have an etchstopper layer.

Therefore, a channel region of the a-Si layer 50 of the TFT is directlyin contact with the organic insulating layer. However, thecharacteristics of the TFT need not be affected.

The TFT substrate may have some other modified structures to compensatethe storage capacitance similar to the second to fourth embodiments ofthe present invention except for the structures of the TFTs.

A flowable insulating layer is also used as a gate insulating layer suchthat the gate insulating layer has the flat surface. According to thesixth embodiment of the present invention, a gate insulating layer isdouble-layered structure including a flowable insulating layer and asilicon nitride layer. FIG. 8 shows a cross-sectional view of a TFTsubstrate according to the sixth embodiment of the present invention,and the layout view of the TFT is substantially the same as FIG. 2.

A flowable organic insulating layer 41 having the thickness of2,500-5,500 Å is formed on a substrate having a gate electrode and astorage capacitor electrode. A silicon nitride layer 42 having thethickness of 500-800 Å is formed between the flowable organic insulatinglayer 41 and an amorphous silicon layer 50.

When only a flowable organic insulating material is used as a gateinsulating layer, the gate insulating layer has a flat surface. However,the characteristics of the amorphous silicon layer formed thereon may bedeteriorated. Therefore, the silicon nitride layer 42 is insertedbetween the flowable organic insulating layer 41 and the a-Si layer 50,and thus, it is possible to make the thickness of a-Si layer less than1,000 Å to reduce photo induced leakage current. However, the siliconnitride layer 42 also may not be used.

As shown in FIG. 8, the silicon nitride (SiNx) layer 41 is formed onlyunder the a-Si layer 50. If the SiNx layer is formed all over theflowable organic insulating layer, the triple layer of the flowableorganic insulating layer, the SiNx layer and the passivation layer isformed at the gate pad region. Because the etch rate of the organicinsulating layer and that of the SiNx are different, it may not be easyto form contact holes in the gate pad region. Therefore, the SiNx layerexcept the portion under the a-Si layer is removed in advance to make iteasier to form the contact holes.

The structure which is not described above is similar to the TFTsubstrate according to the fifth embodiment of the present invention.

The TFT substrate may have some other modified structures to compensatethe storage capacitance similar to the second to fourth embodiments ofthe present invention except for the structures of the TFTs.

The seventh embodiment of the present invention shown in FIG. 9 suggestsa TFT substrate having a metal layer 31 formed on the portion of theorganic insulating layer 41 on the storage capacitor electrode 30 as inthe fourth embodiment of the present invention. The remaining structureis similar to that of the TFT shown in FIG. 8.

According to the eighth embodiment of the present invention, an etchstopper layer is made of an organic material.

FIG. 8 illustrates a cross-sectional view of an etch stopper type TFTsubstrate according to the eighth embodiment of the present invention.According to the eighth embodiment of the present invention, a gateinsulating layer includes an organic insulating layer and an SiNx layeras in the sixth embodiment of the present invention.

An etch stopper layer 61 made of a photo definable organic material isformed between an a-Si layer 50 and an ohmic contact layer 71 and 72.The remaining structure is similar to that of the TFT substrate shown inFIG. 9. The parasitic capacitance between a gate electrode and a drainelectrode causing kickback decreases since the dielectric constant ofthe organic material is relatively low. In addition, the manufacturingprocess is relatively simple since the a-Si layer 50 and the SiNx layer42 is etched using the etch stopper layer 61 as a mask.

The structure which is not described above is similar to the TFTsubstrate according to the sixth embodiment of the present invention.

The TFT substrate may have some other modified structures to compensatethe storage capacitance similar to the second to the fourth embodimentsof the present invention except for the structures of the TFTs-.

The ninth embodiment of the present invention shown in FIG. 11 suggestsa TFT substrate having a metal layer 31 formed on the portion of theorganic insulating layer 41 on the storage capacitor electrode 30 as inthe fourth embodiment of the present invention. The remaining structureis similar to that of the TFT shown in FIG. 10.

FIG. 12 illustrates a cross-sectional view of a color filter substrateaccording to an embodiment of the present invention. As shown in FIG.12, a color filter 160 is formed on a transparent insulating substrate150, and a passivation layer 170 and a common electrode 180 issuccessively formed thereon.

FIG. 13 illustrates a cross-sectional view of a liquid crystal displaycell according to an embodiment of the present invention. The TFTsubstrate and the color filter substrate are arranged such that thecolor filter 160 corresponds to the pixel electrode 140. To keep up thecell gap between the TFT substrate and the color filter substrate, acolumn shaped spacer 190 is formed on the color filter substrate. Thespacer 190 is made of a photo definable organic material, and positionedcorresponding to the TFT on the TFT substrate. The spacer 190 does notaffect the characteristics of the TFT since there are planarized layers100 and 110 having a sufficient thickness on the channel of the TFT.

FIG. 14A illustrates a layout of a color filter substrate to show theposition of spacers, FIG. 148 is a cross-sectional view of the colorfilter substrate illustrated in FIG. 14A along the line XIV-XIV′. InFIGS. 14A and 14B, R, G and B indicate red, green and blue color filtersrespectively. The color filter 160 has a concave shape (a) as shown inFIG. 14A, the spacers 190 are formed there.

Since the spacer 190 is made of a photo definable organic material andmade by photolithography process, the spacers 190 can be placed at thedesired position and the spacers 190 can have a uniform thickness. Forexample, as shown in FIGS. 14A and 14B, the spacers 190 can be formed atthe exact position corresponding to the TFTs on the TFT substrate whichhas a uniform height, and thereby uniform cell gap is obtained. Inaddition, since TFTs are covered with the black matrix and they need notaffect the aperture ratio the spacers 190 need not reduce the apertureratio. Moreover, since the spacers 190 need not be placed on the colorfilters R, G and 8, color filters may have different thickness in orderto have different cell gaps for optimizing the color coordinate and thetransmittance.

Since the spacers 190 have a height, the shading area due to the spacers190 may be generated, which can cause problems in the rubbing process.However, since the width of the spacers 190 can be made sufficientlysmall, the shading area is narrower than the TFTs and shielded by theblack matrix 110.

Referring to FIGS. 15A-17B, a method of manufacturing liquid crystaldisplay according to an embodiment of the present invention will now bedescribed.

FIGS. 15A, 16A and 17A show layouts of intermediate structuresillustrating a method of manufacturing the TFT substrate of the firstembodiment shown in FIGS. 2 and 3. FIGS. 15B, 16B and 17B illustratecross-sectional views of the TFT substrate along the line XV-XV′ of FIG.15A, the line XVI-XVI′ of FIG. 16A and the line XVII-XVII′ of FIG. 17A.

As shown in FIGS. 15A and 15B, a metal pattern of about 3,000 thicknessis deposited and patterned to form a gate electrode 20, a gate line 21and a storage capacitor electrode 30 on a transparent insulatingsubstrate 10. A gate insulating layer 40, an a-Si layer 50, and asilicon nitride layer 60 are deposited thereon in sequence using CVD(chemical vapor deposition) method. The thickness of the gate insulatinglayer 40 is 3,000-6,000 Å, that of the a-Si layer 50 is 500-1,000 Å, andthat of the silicon nitride layer 60 used as an etch stopper is1,000-2,000 Å.

Then, a layer of photoresist is coated on the silicon nitride layer 60,and exposed to light from the rear side of the substrate 10 to form aphotoresist pattern. The silicon nitride layer 60 is etched using thephotoresist pattern as a mask to form an etch stopper layer 60.

Next, heavily doped n+ a-Si layer 71 and 72 is deposited and etched withthe a-Si layer 50. Then, a metal pattern of about 3,000 Å thickness isdeposited and patterned to form a source electrode 80, a drain electrode90 and a data line 81, and the n+ a-Si layer 71 and 72 is etched usingthe source and the drain electrodes 80 and 90 and the data line 81 as amask to form an ohmic contact layer 71 and 72.

Then, as shown in FIGS. 16A and 168, a passivation layer 100 made oforganic insulating material having low dielectric constant and hightransmittance is coated by spin coating, and thereby the passivationlayer 100 can have a flat surface. The dielectric constant of thepassivation layer 100 is preferably 2.4-3.7, and its thickness ispreferably 2.0-4.0 μm. A contact hole 130 exposing the drain electrode90 and a trench 120 exposing the storage capacitor electrode 30 areformed by etching the passivation layer 100. The contact hole 130 andthe trench 120 are formed by dry etching method using O₂, SF₆, and CF₄.In case that the organic insulating material is photo definable, onlythe steps of exposing using a mask and developing the passivation layer100 may be performed.

Next, as illustrated in FIGS. 17A and 17B, an ITO layer is deposited andpatterned to form a pixel electrode 140 in pixel region which is definedby the gate line 21 and the data line 81.

Finally, as shown in FIGS. 2 and 3, the passivation layer 100 is etchedto a depth using the pixel electrode 140 as a mask, and organic blackphotoresist is filled in the groove in the passivation layer 100 to forma black matrix having a flat surface. The etching depth is 05-1.7 μmpreferably, the surface resistance of the organic black photoresist isequal to or more than 10¹⁰ Ω/□. The optical density of the black matrix110 is equal to or more than 2.5.

Referring now to FIGS. 4-6, methods of manufacturing liquid crystaldisplays having different storage capacitors will be described.

To manufacture the TFT substrate according to the second embodiment ofthe present invention, as shown in FIG. 4, after the passivation layer100 is etched to make a trench 120, an exposed portion of the gateinsulating layer 40 is dry etched. Therefore, the portion of the gateinsulating layer 40 on the storage capacitor electrode 30 becomes thinand the storage capacitance becomes large. In this case, to etch thegate insulating layer 40 to a uniform depth, the gate insulating layermay include two layers which have large etching selectivity and only theupper layer may be removed.

To manufacture the TFT substrate according to the third embodiment ofthe present invention, as illustrated in FIG. 5, a portion of the gateinsulating layer 40 on the storage capacitor electrode 30 is etched toform a contact hole 32 before depositing a metal layer for the datalines, the source and the drain electrodes. Then, a metal pattern 31 isformed on the portion of the gate insulating layer 40 on the storagecapacitor electrode 30 simultaneously with a source electrode 80 and adrain electrode 90. The metal pattern 31 is connected to the storagecapacitor electrode 30 through the contact hole 32.

To manufacture the TFT substrate according to the fourth embodiment ofthe present invention, as illustrated in FIG. 6, a metal pattern 31 isformed on the portion of the gate insulating layer 40 on the storagecapacitor electrode 30 simultaneously with a source electrode 80 and adrain electrode 90. The metal pattern 31 is connected to the pixelelectrode 140.

Then, referring to FIGS. 18 and 19, manufacturing method of a TFTsubstrate of the sixth embodiment shown in FIG. 8.

As illustrated in FIG. 18, an organic insulating layer 41 of 2,500-5,500Å thickness is spin coated on a transparent insulating substrate 10having a gate electrode 20, a gate line (not shown) and a storagecapacitor electrode 30, and an SiNx layer 42 of 500-800 Å is depositedthereon using CVD (chemical vapor deposition) method. The organicinsulating layer 41 and the SiNx layer 42 form a gate insulating layer40. On the SiNx layer 42, an a-Si layer 50 and an n+ a-Si layer 70 aredeposited in sequence. The thickness of the a-Si layer 50 is less than1,000 Å.

Then, a layer of photoresist is formed and patterned. The n+ a-Si layer70, the a-Si layer 50 and the SiNx layer 42 are etched in sequence usingthe photoresist pattern as a mask.

Next, as shown in FIG. 19, a metal pattern is deposited and patterned toform a source electrode 80, a drain electrode 90 and a data line (notshown), and the n+ a-Si layer 70 is etched using the source and thedrain electrodes 80 and 90 and the data line as a mask to form an ohmiccontact layer 71 and 72.

The remaining processes are similar to those of the manufacturing methodof the TFT substrate of the first embodiment.

To manufacture the TFT substrate according to the seventh embodiment ofthe present invention, as illustrated in FIG. 9, a metal pattern 31 isformed on the portion of the gate insulating layer 40 on the storagecapacitor electrode 30 when a source electrode 80 is formed. The metalpattern 31 is connected to the pixel electrode 140.

FIGS. 20 and 21 illustrate a manufacturing method of a TFT substrate ofthe eighth embodiment shown in FIG. 10.

As illustrated in FIG. 20, an organic insulating layer 41 of 2,500-5,500thickness is spin coated on a transparent insulating substrate 10 havinga gate electrode 20, a gate line (not shown) and a storage capacitorelectrode 30, and an SiNx layer 42 of 500-800 Å is deposited using CVD(chemical vapor deposition) method. On the SiNx layer 42, an a-Si layer50 of less than 1,000 Å thickness is deposited, and a layer of positivetype photo definable organic material having the thickness of3,000-5,000 Å is coated thereon. Photo BCB, photo definable acrylicpolymer may be used as the organic material. Then, the substrate 10 isexposed to light from the rear side of the substrate 10 by the energy of200-600 mJ (millijoule), and exposed to light again from the front sideof the substrate 10 using a mask which exposes the portion of theorganic insulating layer which becomes the etch stopper layer by theenergy of 50-100 mJ. Next, the organic material layer is developed toform the etch stopper layer 61 and annealed under the N₂ environment atthe temperature of 200-230° C.

Using the etch stopper layer 61 as a mask, the a-Si layer 50 and theSiNx layer 42 are etched. Next, an n+ a-Si layer and a metal layer isdeposited and patterned to form a source electrode 80, a drain electrode90, a data line (not shown), and the n+ a-Si layer 71 and 72 thereunder.

The remaining processes of the manufacturing method are similar to thoseof the manufacturing method of the TFT substrate of the firstembodiment.

In the manufacturing method of the TFT substrate of the ninthembodiment, as illustrated in FIG. 11, the processes for forming TFT aresimilar to those of the manufacturing method of the TFT substrate of theeighth embodiment. The remaining processes are similar to those of themanufacturing method of the TFT substrate of the fourth embodiment.

Now, referring to FIG. 12, manufacturing method of a color filtersubstrate according to an embodiment of the present invention. Asillustrated in FIG. 12, a layer of color resist is formed on atransparent substrate 150, and color filters 160 are formed using photoetching process for the color resist layer. A passivation layer 170 isformed on the color filters 160, and an ITO common electrode 180 isformed thereon.

Next, as shown in FIG. 13, an organic insulating layer is formed on thecommon electrode 180 and patterned to form column shaped spacers 190.The spacers 190 are placed on the TFT on the TFT substrate.

Finally, an empty liquid crystal cell is made by assembling the TFTsubstrate and the color filter substrate, liquid crystal materials arefilled in the cell, and driving ICs are added to complete liquid crystaldisplay, as shown in FIG. 13.

According to the present invention, since the black matrix is formedusing the pixel electrode as an etching mask, the aperture ratio can beincreased. In addition, since the passivation layer and/or the gateinsulating layer are made of organic materials having flat surfaces, theheight difference between patterns can be reduced.

In the case that the etch stopper layer is made of the organicinsulating layer having low dielectric constant, the parasiticcapacitance between the gate electrode and the drain electrode can bedecreased.

On the other hand, because the spacers are formed using photo definableorganic material, the positions of the spacers can be controlled.Accordingly, by placing the spacers at suitable positions, theuniformity of the cell gap can be obtained, and a decrease of thetransmittance can be prevented.

In the drawings and specification, there have been disclosed typicalpreferred embodiments of the invention and, although specific terms areemployed, they are used in a generic and descriptive sense only and notfor purposes of limitation, the scope of the invention being set forthin the following claims.

1-45. (canceled)
 46. A liquid crystal display comprising: a first insulating substrate; a gate pattern that comprises a gate electrode and a gate line that is disposed on the first insulating substrate; a gate insulating layer that covers the gate pattern; a semiconductor layer disposed on the gate insulating layer; a data pattern that comprises a drain electrode and a source electrode, which are disposed on the semiconductor layer, and a data line that is connected to the drain electrode; a passivation layer that comprises organic insulating material and has a contact hole that exposes the drain electrode; a pixel electrode that is connected to the drain electrode through the contact hole; a second insulating-substrate that faces the first insulating substrate; a black matrix that overlaps the gate line or the data line; and spacers formed at a region covered by the black matrix between the first insulating substrate and the second insulating substrate.
 47. The liquid crystal display of claim 46, wherein the dielectric constant of the passivation layer is in a range of about 2.4-4.7.
 48. The liquid crystal display of claim 46, wherein the passivation layer has a flat surface.
 49. The liquid crystal display of claim 46, wherein the pixel electrode overlaps at least a portion of the data pattern.
 50. The liquid crystal display of claim 46, wherein the black matrix is disposed in a groove of the passivation layer.
 51. The liquid crystal display of claim 46, further comprising an etch stop layer that is disposed between the semiconductor layer and the passivation layer.
 52. The liquid crystal display of claim 46, wherein the black matrix is formed using photolithography. 